Contact tray having tray supported downcomers and methods involving same

ABSTRACT

A plurality of fluid-fluid contact trays of the cross-flow type are provided within a shell of a mass transfer or heat exchange column. The trays include tray decks that are supported on rings fixed to an inner surface of the shell and downcomers that are supported, not by the typical bolting bars fixed to the shell, but by the tray deck of the underlying tray. The mechanisms for supporting the downcomers in this fashion are support brackets that are not secured to the column shell, but instead extend downwardly from the downcomers and rest on the tray deck of the underlying tray. Alternating trays have side downcomers positioned at openings at one or both ends of the tray deck. The support rings on those trays having side downcomers may be truncated so that the rings do not extend around that portion of the shell circumference where the side downcomer openings are located. On the remaining trays, complete 360 degree rings may be used. Some or all of the downcomers have an inwardly extending shoulder segment in one or both side walls that supports portions of the tray deck and contains fluid passages.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This is a divisional application of U.S. application Ser. No.10/172,914, filed on Jun. 17, 2002, now pending, which claims thebenefit of provisional application Serial No. 60/298,962, filed Jun. 18,2001.

BACKGROUND OF THE INVENTION

[0002] The present invention is directed to mass transfer devices and,more particularly, to vapor-liquid contact trays and methods of makingand utilizing such trays.

[0003] Various types of trays are commonly used in mass transfer columnsto promote contact and mass transfer between ascending and downwardlyflowing fluid streams. The ascending fluid is typically vapor and thedescending fluid is typically liquid, although liquid-liquid andgas-liquid systems are also known. Each tray normally extendshorizontally across substantially the entire horizontal cross section ofthe column and is supported around its perimeter by a ring welded to theinner surface of the circular column wall or shell. A number of traysare positioned in this manner with a uniform vertical spacing betweenadjacent trays. The trays may be located in only a portion of the columnto perform one part of a multi-step process occurring with the column.Alternatively, the trays may fill substantially the entire open areawithin the column.

[0004] Trays of the type described above contain one or more downcomersthat are positioned at openings in the tray deck to provide passagewaysfor liquid to descend from one tray to an adjacent lower tray. Prior toentering the downcomer, the liquid on the tray deck interacts withascending vapor that passes through openings provided in selectedportions of the tray deck. Those areas of the tray deck containing vaporopenings are commonly referred to as “active” areas because of the vaporand liquid mixing and frothing that occurs above those areas of thetray. The downcomer inlets on vertically adjacent trays may extend inlaterally opposite directions to promote more uniform lateraldistribution of the descending liquid or they may extend in a parallelbut offset relationship.

[0005] At least two broad categories of trays are used in mass transfercolumns. The first category of trays is referred to as counter-flowtrays or multiple downcomer trays and is characterized by a relativelylarge number of downcomers positioned on each tray. In counter-flowtrays, the downcomers are generally trough-shaped and extend above thetray so that liquid must accumulate on the tray surface before enteringthe inlet to the downcomer. The lower outlet of such downcomers utilizesa perforated plate that causes liquid to accumulate within the downcomerto seal the outlet against the entry of ascending vapor into thedowncomer where it would impede the descending flow of liquid. The loweroutlet of this type of downcomer is normally located well above the deckof the tray below and above the inlet of the downcomers on the traybelow.

[0006] The second broad category of trays is referred to as cross-flowtrays and differs from counter-flow trays in several significantrespects. First, the number of downcomers utilized in cross-flow traysis normally less than the number used in counter-flow trays. Cross-flowtrays normally use a side downcomer located at opposite ends of adjacenttrays, although in multiple pass configurations one or more additionaldowncomers are located at intermediate locations on each cross-flowtray. Downcomers on cross-flow trays normally discharge liquid onto animperforate receiving pan located on the tray below and inlet weirs areprovided adjacent the receiving pan to cause liquid to accumulate abovethe level of the downcomer outlet to seal against entry of vapor intothe downcomer. By contrast, as discussed above, counter-flow traydowncomers use a perforated discharge plate rather than an inlet weir toform the liquid seal and liquid is discharged onto the active area ofthe underlying tray rather than onto an imperforate seal pan.

[0007] Counter-flow and cross-flow trays also differ in the manner inwhich they are constructed and installed in a column. Counter-flow traysare normally supported entirely on the support rings that are welded tothe inner surface of the column shell. Because the downcomer outlets incounter-flow trays are located well above the tray below, somevariations in tray spacing resulting from deviations in ring placementand downcomer construction can be accommodated without significantlyaffecting tray performance. As a result, each downcomer and tray panelin a counter-flow tray is normally preassembled and then simply carriedinto the column through a manway or other opening and positioned on thesupport ring.

[0008] By contrast, the downcomers in cross-flow trays extend almostcompletely to the tray below and must be carefully positioned to ensurethat the proper vertical clearance is provided between the lower edge ofthe downcomer and the imperforate seal pan on the tray below. Variationsin this vertical clearance can significantly affect the amount of liquidthat can be discharged from the downcomer and may result in detrimentalflooding of the downcomer and column. Because the vertical clearance isso important, the downcomer is normally assembled within the columnusing multiple pieces so that the lower wall or apron of the downcomercan be adjusted to provide the proper vertical clearance.

[0009] The downcomers in counter-flow and cross-flow trays also differin the manner in which they are supported in the column. Counter-flowdowncomers are box-like in configuration and normally do not extendcompletely across the column cross section in order to simplifyinstallation of the trays. Because fewer downcomers are normally used incross-flow trays, they traditionally extend completely across thehorizontal cross section of the column to maximize the total liquidcarrying capacity of the downcomers. Normally the column shell forms theshort end walls of these downcomers and, in the case of side downcomers,one of the longitudinally extending downcomer side walls. The remainingside walls of each downcomer are attached to the column shell usingnumerous vertically extending and inclined bolting bars that areprepositioned and welded to the inner surface of the column shell.Location and installation of these bolting bars is a time-consuming andlabor-intensive task that can add significantly to the installation costof cross-flow trays. Moreover, if the bolting bars are misaligned,installation of the downcomer is made more difficult and/or theimportant vertical discharge clearance at the downcomer outlet may beadversely affected.

[0010] A need has thus developed for a cross-flow tray that is easier toinstall and does not require the use of downcomer bolting bars.

BRIEF SUMMARY OF THE INVENTION

[0011] In one aspect, the present invention is directed to a masstransfer or heat exchange column having an upright shell that defines anopen internal region and has an inner surface with a circumference ofpreselected length. A first tray support in the nature of a partial orcomplete support ring is attached to the inner surface of the shell andextends in a first plane around at least a portion of the circumferenceof the inner surface of the shell. A second tray support also in thenature of a support ring or segments thereof is attached to the innersurface of the shell and extends in a second plane spaced a preselecteddistance below the first plane around at least a portion of thecircumference of the inner surface of the shell. A first tray and anunderlying second tray are positioned within the shell and each tray isof similar construction and comprises a tray deck having an active areaand opposed ends and opposed sides. At least one and normally aplurality of downcomers are each positioned at an opening in the traydeck and extend in a downward direction for removing liquid followinginteraction with vapor on the tray deck. The tray deck of the first trayis supported by said first tray support and the tray deck of the secondtray is supported by the second tray support. At least one supportbracket extends downwardly from one or more of the downcomers of thefirst tray to the underlying second tray and supports the associateddowncomers of the first tray on the underlying second tray. In thismanner, the support brackets allow the desired downcomer clearance to bemaintained even though there may be variances in the placement of thesupport rings. Moreover, the elimination of bolting bars that areconventionally welded to the column shell allows for quicker and lesscostly assembly of the trays 16 within the column 10.

[0012] In another aspect, the invention is directed to a method ofinstalling a plurality of the contact trays within a new or revampedmass transfer or heat exchange column. The method includes the steps ofproviding a first tray support attached to the inner surface of theshell and extending in a first plane around some or substantially theentire circumference of the inner surface of the shell. A second traysupport is attached to the inner surface of the shell and extends in asecond plane spaced a preselected distance below the first plane aroundsome or substantially the entire circumference of the inner surface ofthe shell. A first tray and an underlying second tray of the typedescribed herein are carried into the column through suitable manways orother openings and are assembled with the tray deck of the first traysupported on the first tray support and the tray deck of the second traysupported on the second tray support. The downcomers of at least thefirst tray and preferably both the first and second trays are supportedentirely on the tray deck of the underlying trays.

[0013] The present invention is also directed to a contact traycomprising a tray deck having vapor apertures for permitting vapor toascend through the tray for mixing with liquid flowing across the traydeck, an elongated opening in the tray, and a downcomer positioned atthe opening for removing liquid from the tray deck. The downcomercomprises spaced apart side walls and end walls that extend between theside walls to close opposite ends of the downcomer. Each of the sidewalls comprises a lower segment, an upright intermediate segment and aninwardly extending shoulder segment. At least one of the lower segmentsis inclined toward the other lower segment to from a lower dischargeoutlet having a preselected open area in a horizontal plane which isless than a horizontal cross-sectional area between the intermediatesegments of the downcomer. Portions of the tray deck overlap and aresupported on the shoulder segments. Aligned fluid passage openings inthe shoulder segments and the overlapped portions of the tray deck allowliquid entry into the downcomer during start up. Following start up, thefluid passage openings also permit vapor that has separated from liquidin the downcomer to exit the downcomer without impeding liquid entryinto the downcomer inlet. Advantageously, each downcomer side wall andan associated weir are of a one-piece construction formed by folding asingle sheet of metal.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0014] In the accompanying drawings which form part of the specificationand in which like reference numerals are used to indicate like parts inthe various views:

[0015]FIG. 1 is a fragmentary perspective view of a mass transfer columncontaining cross-flow trays constructed in accordance with oneembodiment of the present invention;

[0016]FIG. 2 is an enlarged, fragmentary elevation view of the columnand a plurality of trays taken in vertical section along line 2-2 ofFIG. 1;

[0017]FIG. 3 is a top plan view of the column and tray;

[0018]FIG. 4 is an enlarged, fragmentary elevation view of a portion ofthe tray containing a downcomer, with an end wall of the downcomer beingbroken away for illustration purposes;

[0019]FIG. 5 is a fragmentary end perspective view of the downcomershown in FIG. 4;

[0020]FIG. 6 is a top plan view of the downcomer taken along line 6-6 ofFIG. 4 in the direction of the arrows;

[0021]FIG. 7 is top plan view of the downcomer taken in horizontalsection along line 7-7 of FIG. 4 in the direction of the arrows;

[0022]FIG. 8 is a fragmentary top plan view of the column showing aportion of a side downcomer supported on an underlying tray;

[0023]FIG. 9 is a fragmentary side elevation view of the column taken invertical section along line 9-9 of FIG. 8 and showing the manner inwhich the side downcomer is support on the underlying tray; and

[0024]FIG. 10 is an enlarged fragmentary perspective view showing one ofthe brackets used to support one end of the side downcomer.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Referring now to the drawings in greater detail, and initially toFIGS. 1-3, a mass transfer or heat exchange column is designatedgenerally by the numeral 10 and includes an upright cylindrical shell 12which defines an open interior region 14 in which a plurality offluid-fluid contact trays 16 are located. The trays 16 are of across-flow design and are normally used for facilitating vapor-liquidfractionation or other contact, but may also be used in liquid-liquidand gas-liquid applications. Column 10 is of a type used for processingliquid and vapor streams, including to obtain fractionation products.Although column 10 is shown in a cylindrical configuration, othershapes, including polygonal, may be used. The column 10 can be of anysuitable diameter and height and can be constructed from suitable rigidmaterials.

[0026] One or more liquid streams can be directed to the column 10 in aconventional manner through feed lines that are not shown because oftheir conventional nature. Likewise, one or more vapor streams can becharged to the column or can be generated within the column. In additionto trays 16, internals such as beds of packing can be located within thecolumn to carry out other desired processing of the liquid and vaporstreams. Other appropriate system components such as connections andlines for feed, product removal and reflux streams, reboilers,condensers, and the like are not illustrated because of theirconventional nature.

[0027] The trays 16 of the present invention are positioned in theinterior region 14 of column 10 and are located in vertically spacedapart relationship. The trays 16 are generally horizontally disposed andare supported on rings 18 that are welded or otherwise mounted on theinner surface of the column shell 12. As more fully described below,some rings 18 extend completely around the inner circumference of thecolumn 10, while others are formed as two or more spaced apart ringsegments that circumscribe only selected portions of the innercircumference of the column.

[0028] Each tray 16 comprises a tray deck 20 formed from a plurality ofgenerally coplanar panels 22 that are spaced apart to form a pluralityof elongated openings. Downcomers 24 are positioned in these openings toremove liquid from the tray deck 20 and convey it to the next underlyingtray 16 through a lower discharge outlet 25. The two panels 22 at theopposite ends of alternate trays 16 are similarly spaced from columnshell 12 to form a chordal opening in which side downcomers 26 arepositioned. The downcomers 24 are oriented so that their longerhorizontal dimensions extend in the same direction, but downcomers 24 onadjacent trays 16 are staggered so that they are not in verticalalignment.

[0029] The panels 22 of the tray deck 20 include a plurality of vaporflow apertures 28 uniformly distributed across the portion of the traydeck known as the “active area.” The apertures 28 permit vapor to passthrough the tray deck and interact with liquid flowing across the uppersurface of the deck. The apertures 28 have a size, shape anddistribution selected for the particular operating conditions in whichthe tray 16 will be utilized. As best shown in FIG. 8, the apertures 28can be punched valves of a conventional design. Alternatively, theapertures 28 can be moveable valve units or simple sieve holes.

[0030] Each tray deck panel 22 is supported at its opposite ends by thesupport ring 18 welded to the column shell 12. In those portions of thetray deck 20 where no panels 22 are located, portions of the supportring 18 can be omitted to simplify the installation process. Forexample, the support ring 18 need not be present at those portions ofthe trays 16 where the side downcomers 26 are located. As can best beseen in FIGS. 4 and 5, the sides of deck panels 22 partially overlap andare supported by T-shaped beams 30 that extend in the same longitudinaldirection as the deck panels 22. The T-shaped beams 30 are likewisesupported at their opposite ends by the support ring 18. Each beam 30 ispreferably formed from two pieces of flat metal stock that are bent intoan inverted L-shape and are then joined together to form the T-shape ofthe beam. Other fabrication techniques, of course, are available andoptional gussets 31 may be used for strengthening purposes. The verticalleg of the beam 30 functions as an anti-jump baffle 32 to help to directliquid into the vertically aligned downcomer 24 on the tray below. Aplurality of openings 33 may be formed in the baffle 32 to permit vaporto flow through the baffle 32 to equalize the pressure on both sidesthereof.

[0031] The laterally or horizontally extending portions of T-shapedbeams 30 form an inlet panel 34 that underlies the downcomers 24extending downward from the tray 16 above. Two parallel and spaced apartrows of box-shaped bubble promoters 36 are positioned on the uppersurface of the inlet panel 34 above openings (not shown) formed in theinlet panel 34 to permit vapor entry into the bubble promoters 36.

[0032] An elongated liquid receiving pan 38 is centrally positionedbetween the rows of bubble promoters 36 on top of the inlet panel 34 andextends along the length of the inlet panel 34. The receiving pan 38 isin vertical alignment with the discharge outlet 25 of the overlyingdowncomer 24 so that it receives the liquid discharged from theoverlying downcomer 24. The receiving pan 38 is preferably imperforateto prevent the downward flowing liquid from weeping through thereceiving pan 38 and thereby bypass the intended interaction with vaporon the tray deck.

[0033] Positioned along both sides of the receiving pan 38 are weirs 40that extend upwardly a preselected distance to cause liquid dischargedfrom the overlying downcomer 24 to accumulate on the receiving pan 38 toform a liquid seal that impedes entry of vapor into the discharge outlet25 of the overlying downcomer 24. The receiving pan 38 and weirs 40 arepreferably of a single-piece construction formed by bending upwardly thelongitudinal sides of a piece of elongate flat metal stock.

[0034] Each downcomer 24 comprises a pair of longitudinally extendingand spaced apart side walls 42 and a pair of end walls 44 that aresecured to ends of the side walls 42. The spacing between the verticallyextending upper portions of the side walls 42 forms an inlet 46 forliquid to enter the downcomer 24. The lower or apron portions of theside walls 42 are angled toward each other to form the discharge outlet25 which has a smaller cross-sectional area than the inlet 46 so thatsome liquid will accumulate within the downcomer during operation of thecolumn 10. A pair of spaced apart weirs 48 is formed along the downcomerinlet 46 so that liquid will accumulate on the tray deck 20 for vaporinteraction prior to entering downcomer 24. Each downcomer side wall 42and associated weir 48 are of a one-piece construction formed by bendingflat metal stock. In this manner, the weir 48 is formed integrally withthe side wall 42 and is connected to a horizontal flange 50 that extendsinwardly from the upper portion of the side wall 42. As can best be seenin FIGS. 5 and 6, the flange 50 and overlapped portions of the tray deck20 advantageously include a plurality of spaced apart and alignedopenings 52 that function as start up spouts to permit liquid entry intothe downcomer 24 at the low flow rates present during start up of thecolumn 10. It can be seen that the horizontally extending flange 50 alsosupports the overlapped portions of the tray deck 20 and allows theupper portion of the side walls 42 to be displaced outwardly to increasethe internal volume of the downcomer 24. After start up, the openings 52contained in the flange 50 and tray deck 20 providing a ready flow pathfor vapor to exit the internal volume of the downcomer 24 afterdisengaging from the liquid therein.

[0035] Each downcomer 24 includes a support bracket 54 secured to thelower portion of each downcomer end wall 44. The support bracket 54extends downwardly below the end wall 44 a preselected distancecorresponding to the desired vertical discharge clearance at thedowncomer outlet 25. When the downcomer 24 is positioned in the column10, the support brackets 54 rest on the receiving pan 38 of theunderlying tray 16. In this manner, the support brackets 54 carry theentire weight of the downcomer 24 and transfer it to the T-shaped beam30 on the tray 16 below. The downcomers 24 thus do not need to besupported on the same ring 18 as the tray 16 from which the downcomerdescends. Because the support brackets 54 transfer the weight of thedowncomer 24 to the tray below, the downcomers 24 do not need to besupported by vertical bolting bars as is the case with conventionalcross-flow trays. Moreover, because the support brackets 54 maintain thedesired vertical clearance between the downcomer discharge outlet 25 andthe underlying receiving pan 38, the downcomer 24 need not be of amultiple piece construction as is conventionally necessary to permitadjustment of the downcomer apron to obtain the desired verticaldischarge clearance. As a result, the downcomer side walls 42 can be ofa one-piece construction and the downcomer can be preassembled outsideof the column 10 and then simply carried through a manway and positionedon the underlying tray 16. By eliminating the need to install boltingbars and assemble the downcomer from multiple pieces within the column,substantial time and expense can be saved in the installation ofdowncomers 24.

[0036] Each support bracket 54 comprises a generally planar body 56 anda pair of vertically extending stiffening flanges 58. An opening 60 ispreferably formed in the body 56 to permit fluid to flow through thebracket 54. The bracket 54 can be welded, bolted or otherwise secured tothe outer face of the downcomer end wall 44.

[0037] Turning additionally to FIGS. 8 and 9, each side downcomer 26 canbe supported on the underlying tray 16 in a manner similar tointermediate downcomers 24. The side downcomers 26 are chordal inconfiguration and include a multi-segmented, semi-conical lower skirt62. A support bracket 64 is secured to the underlying tray panel 22 at alocation to receive and support the downcomer skirt 62. The bracket 64is generally U-shaped and is cut out to form an L-shape in side profile.In this manner, the bracket 64 functions to provide the desired verticalclearance between the lower discharge end of the downcomer skirt 62 andthe underlying tray panel 22 and also positions the downcomer skirt 62the desired horizontal distance from the column shell 12. As can best beseen in FIGS. 9 and 10, a pair of support brackets 66 are also securedto opposite ends of the downcomer 26 to provide additional support forthe downcomer 26 on the underlying tray deck 20. The support brackets 66are each of a two-piece construction with a lower L-shaped leg 68 thatis moveably secured to the underlying tray deck 20. Various methods ofsecuring the leg 68 to the trays deck 20 can be utilized, including afastener 70, such as a nut and bolt, that extends through a closed-endedslot 72 in the tray deck 20 and an opening (not shown) in the leg 68.The slot 72 allows adjustment of the positioning of the leg 68 inrelation to the shell 12, with the leg 68 preferably being adjusted sothat it abuts the shell 12 and provides a partial seal thereagainst.Each support bracket 66 also includes an upper segment 74 that has avertical plate 76 that is secured to the downcomer skirt 62 by fasteners70 that extend through adjustment slots 78 in the downcomer skirt 62.The upper segment 74 includes a flange 80 that extends at 90 degreesfrom a vertical edge of the plate 76 and is secured to the lower leg 68by a pair of the fasteners 70. A horizontally extending flange 82extends along the upper edge of the plate 76 and is secured to thesupport ring 18 for the overlying tray deck 20. It can be seen that themethod described herein for supporting the downcomers 24 and sidedowncomers 26 entirely on the underlying tray deck 20 allows the trays16 to be readily assembled within the column 12 without the delays andexpense associated with bolting bars that are conventionally welded tothe inner surface of the column shell 12 to provide support for thedowncomers. Further installation savings are obtained by using supportring segments only in those portions of the shell 12 circumference wherethe tray deck 12 requires support. The openings in the tray deck 20where the downcomers are located, particularly the side downcomers 26,do not require the presence of the support rings 18. Omitting thesupport rings 18 from these areas can also increase the capacity of thedowncomers by increasing the open area for liquid entry into thedowncomer inlet 46. In other applications, such as existing columns, theuse of complete support rings 18 may be desirable or even preferred.

[0038] The present invention includes a method of constructing thecolumn 10, comprising the steps of providing a first support ring 18attached to the inner surface of the shell 12 and extending in a firstplane around the circumference of the inner surface of the shell 12. Asecond support ring 18 is attached to said inner surface of the shell 12and extends in a second plane spaced a preselected distance below thefirst plane around the circumference of the inner surface of the shell12. The tray decks 20 of a first tray 16 and an underlying second tray16 are supported on the first and second support rings 18, respectively,while the downcomers 24 and/or 26 of the first tray 16 are supportedentirely on the tray deck 20 of the underlying second tray 16.

[0039] From the foregoing it will be seen that this invention is onewell adapted to attain all ends and objectives hereinabove set forthtogether with the other advantages which are inherent to the structure.

[0040] It will be understood that certain features and subcombinationsare of utility and may be employed without reference to other featuresand subcombinations. This is contemplated by and is within the scope ofthe claims.

[0041] Since many possible embodiments may be made of the inventionwithout departing from the scope thereof, it is to be understood thatall matter herein set forth or shown in the accompanying drawings is tobe interpreted as illustrative, and not in a limiting sense.

Having thus described the invention, what is claimed is:
 1. A method ofinstalling a plurality of contact trays within a mass transfer or heatexchange column comprising a shell defining an open internal region andhaving an inner surface with a preselected circumference, said methodcomprising the steps of: providing a first tray support attached to saidinner surface of the shell and extending in a first plane around some orsubstantially the entire circumference of the inner surface of theshell; providing a second tray support attached to said inner surface ofthe shell and extending in a second plane spaced a preselected distancebelow the first plane around some or substantially the entirecircumference of the inner surface of the shell; providing a first trayand an underlying second tray, both said trays comprising a tray deckhaving vapor passages and opposed ends and opposed sides and a pluralityof downcomers positioned at openings in the tray deck and extendingdownwardly for removing liquid when present on the tray deck; andsupporting said tray deck of the first tray on said first tray supportand said tray deck of the second tray on said second tray support. 2.The method of claim 1, including supporting the downcomers of said firsttray on said second tray.
 3. The method of claim 1, including supportingthe downcomers of said first tray on the tray deck of said second tray.4. The method of claim 1, including supporting the downcomers of saidfirst tray entirely on said second tray.
 5. The method of claim 1,including the steps of supporting portions of the tray deck of thesecond tray on a horizontally extending beam having opposite endssupported on the second tray support and supporting the downcomers ofsaid first tray at least partially with said beam.
 6. The method ofclaim 1, including positioning one of said openings at one end of saidtray deck and providing a side downcomer at said one opening.
 7. Themethod of claim 6, including securing moveable support brackets atopposite ends of said side downcomer to support said side downcomer onthe tray deck of the second tray, said moveable support brackets beingfree of attachment to the inner surface of said shell.
 8. The method ofclaim 7, including abutting said moveable support brackets against theinner surface of said shell.
 9. The method of claim 1, includingconstructing at least some of said downcomers with spaced apart sidewalls and end walls extending between the side walls to close oppositeends of the downcomer, each of said side walls comprises a lowersegment, an upright intermediate segment and an inwardly extendingshoulder segment, wherein at least one of said lower segments isinclined toward the other lower segment to from a lower discharge outlethaving a preselected open area in a horizontal plane which is less thana horizontal cross-sectional area between said intermediate segments ofthe downcomer.
 10. The method of claim 9, including overlapping portionsof said tray deck on said shoulder segments to provide support for saidtray deck.
 11. The method of claim 10, including providing alignedopenings in said shoulder segments and said overlapped portions of thetray deck.
 12. The method of claim 11, including providing weirsextending upwardly from inner edges of said shoulder segments.
 13. Themethod of claim 12, including forming at least one of the side walls ina one piece construction.
 14. A contact tray comprising: a tray deckhaving vapor apertures for permitting vapor to ascend through the trayfor mixing with liquid flowing across the tray deck; an elongatedopening in the tray; a downcomer positioned at the opening for removingliquid from the tray deck when present thereon, said downcomercomprising spaced apart side walls and end walls extending between theside walls to close opposite ends of the downcomer, each of said sidewalls comprises a lower segment, an upright intermediate segment and aninwardly extending shoulder segment, wherein at least one of said lowersegments is inclined toward the other lower segment to from a lowerdischarge outlet having a preselected open area in a horizontal planewhich is less than a horizontal cross-sectional area between saidintermediate segments of the downcomer, and wherein portions of saidtray deck overlap and are supported on said shoulder segments; andaligned fluid passage openings in said shoulder segments and saidoverlapped portions of the tray deck.
 15. The contact tray of claim 14,including weirs extending upwardly from inner edges of said shouldersegments.
 16. The contact tray of claim 15, wherein at least one of saidside walls is of a one-piece construction.